Floor Grid Panel Barrier Layer Melting for Stability
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Solution Overview
Problem
Existing grid panels for floor attachment lack stability due to the barrier layer not being designed to handle load forces directly, as the force is transferred from the lattice bars to the barrier layer, which is not intended for such loads.
Innovation Solution
The barrier layer is melted in contact areas with the lattice structure, allowing it to be present exclusively within the lattice openings, enabling the lattice webs to directly contact the subsoil and providing improved stability, with the barrier layer forming a permeable net or fleece for drainage and material retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the barrier layer rests on the lattice bars to provide coverage and material retention, then the barrier layer can hold filling material in the grid openings, but the force is transferred to the barrier layer instead of directly to the subsoil, reducing structural stability
Solution Approach 1:
The barrier layer is melted in the contact areas with the lattice structure, transitioning from a solid state that could bear load to a molten state that bonds to the lattice structure upon cooling. This phase transition during manufacturing creates a strong bond while eliminating the barrier layer's ability to bear load in contact areas, ensuring all load transfers directly to the subsoil through the lattice structure.
Solution Approach 2:
The physical state of the barrier layer is changed from solid to molten in the contact areas with the lattice structure. This parameter change (temperature-induced phase transition) allows the barrier layer to bond strongly to the lattice structure while preventing it from bearing load, as the molten material conforms to and bonds with the lattice structure upon cooling.
2Reliability
If the barrier layer covers the lattice structure to retain filling material, then material retention is improved, but the appearance on the reverse side is degraded as structural elements are covered
Solution Approach 1:
The barrier layer is selectively melted only in the contact areas with the lattice structure, while remaining intact within the grid openings. This creates local quality differences: in contact areas, the melted barrier layer bonds to the lattice structure and becomes invisible, while in grid openings, the barrier layer remains to retain filling material. This local differentiation resolves both the appearance and material retention requirements.
3Ease of manufacture
If the barrier layer is used to connect to the lattice structure through contact areas, then manufacturing is simplified, but the height of the grid panel is increased and load transfer is compromised
Solution Approach 1:
The barrier layer is melted during the injection molding process, transitioning from solid to molten state. This allows the barrier layer to conform to and bond with the lattice structure in contact areas, creating a strong connection without requiring additional height. The molten material flows into contact areas and bonds upon cooling, achieving connection without increasing panel height.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances the stability and appearance of the grid panel by allowing direct force transfer to the subsoil, while maintaining the barrier layer's function in retaining bulk materials and allowing water drainage, and simplifies manufacturing through injection molding or 3D printing processes.
Implementation Method 1
the barrier layer is melted in contact areas with the lattice structure in such a way that the barrier layer is present essentially exclusively within the lattice openings
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a floor-mounted grid panel with a grid structure made of grid bars (11) that define grid openings, and with a barrier layer (20) that covers the grid openings, wherein the grid structure and the barrier layer (20) are bonded together. The invention is characterized in that the barrier layer (20) is melted in contact areas with the grid structure such that the barrier layer (20) is present essentially exclusively within the grid openings.